Cladding panel

ABSTRACT

A prefabricated reinforced brick panel has a plurality of bricks arranged in a spaced-apart array with mortar between the bricks. The array comprises a number of superimposed rows of bricks. The bricks in each row are staggered relative to the bricks in each adjacent row of bricks. Each brick has a number of vertical through holes extending between a top and a bottom of the brick. These through holes are aligned in the array and vertical reinforcing bars are inserted into aligned holes and extend between a top and a bottom of the panel. Two offset vertical reinforcing bars pass through each brick. Transverse reinforcing bars are mounted in the mortar between rows of bricks.

RELATED APPLICATION

This application claims the priority of the following application, whichis herein incorporated by reference: Irish Application No.: S2006/0809;filed on 2 Nov. 2006.

FIELD OF THE INVENTION

This invention relates to cladding panels, and in particular toprefabricated reinforced masonry panels.

THE BACKGROUND ART

Examples of prefabricated reinforced masonry panels are to be found inPatent Specification Nos. GB 2,407,828, WO 03/104577, GB 1,219,587, GB1,149,741 and GB 1,094,574. While a number of such cladding panels havebeen proposed previously, for one reason or another these have notproven entirely satisfactory and do not appear to have found widespreaduse.

The present invention is directed towards providing an improved claddingpanel and method of manufacturing such cladding panels.

SUMMARY OF THE INVENTION

According to the invention, there is provided a method for manufacturinga prefabricated reinforced masonry panel, including the steps:

-   -   laying a plurality of bricks face down on a horizontal support        surface of a panel forming bed in a spaced-apart array leaving        gaps between the bricks for reception of mortar,    -   said array comprising a number of juxtaposed rows of bricks,    -   the bricks in each row of bricks being staggered relative to the        bricks in each adjacent row of bricks,    -   each brick having a plurality of spaced-apart through holes        extending between a top and a bottom of the brick,    -   overlapping said holes in adjacent rows of bricks when forming        said array,    -   inserting a number of spaced-apart outer vertical reinforcing        bars through said overlapping holes in the bricks in alignment,    -   said outer vertical reinforcing bars extending between a top row        of the bricks and a bottom row of the bricks in said array of        bricks,    -   laying a first transverse reinforcing bar across said outer        vertical reinforcing bars along at least one of the gaps between        rows of bricks,    -   inserting a number of inner vertical reinforcing bars through        said overlapping holes in the bricks in alignment,    -   said inner vertical reinforcing bars extending between the top        row of bricks and the bottom row of bricks in said array of        bricks and spaced above the outer vertical reinforcing bars on        the bed,    -   preparing a liquid mortar and pouring said liquid mortar into        the gaps between the bricks and through the holes in the bricks,    -   allowing the mortar to set to form the prefabricated reinforced        masonry panel, and    -   removing the prefabricated reinforced masonry panel from the        bed.

In one embodiment of the invention, the method includes laterallyoffsetting the inner and outer vertical reinforcing bars.

In another embodiment, the method includes inserting two verticalreinforcing bars through each brick.

In a preferred embodiment, the method includes inserting one outervertical reinforcing bar and one inner vertical reinforcing bar througheach brick.

In another embodiment, the method includes laying a second transversereinforcing bar across said inner reinforcing bars along at least one ofthe gaps between rows of bricks prior to pouring the liquid mortar intothe gaps between the bricks.

In another embodiment, the method includes laying first and secondtransverse reinforcing bars in all the gaps between the rows of bricks.

In a further embodiment, each transverse reinforcing bar extends betweenopposite sides of the brick array.

In another embodiment, the reinforcing bars comprise rebar.

In a further embodiment, the method includes preparing a liquid mortarby mixing together a fine sand, cement and water.

In another embodiment, the method includes the step of arranging thebricks on the bed for forming an ope in the wall panel. The ope may beprovided, for example, for reception of a window or door assembly.

In another embodiment, means is provided for sealing between a face ofeach brick and the bed.

In another embodiment, said sealing means extends into the gaps betweenthe bricks.

In a further embodiment, the sealing means comprises resilient sealingelements mounted on the bed in the gaps between the bricks.

In another aspect, the invention provides a prefabricated reinforcedmasonry panel, including:

-   -   a plurality of bricks arranged in a spaced-apart array of bricks        with mortar between the bricks,    -   said array comprising a number of superimposed rows of bricks,    -   the bricks in each row of bricks being staggered relative to the        bricks in each adjacent row of bricks,    -   each brick having a plurality of through holes extending between        a top and a bottom of the brick,    -   holes in each brick being in alignment with associated holes in        vertically adjacent bricks,    -   a transverse reinforcing bar mounted between at least two        adjacent rows of bricks,    -   a number of spaced-apart vertical reinforcing bars extending        through aligned holes in the bricks between a top row of the        bricks and a bottom row of the bricks in the brick array,    -   two vertical reinforcing bars extending through each full brick        in the array.

In another embodiment, an outer vertical reinforcing bar and an innervertical reinforcing bar extend through each brick, said outer verticalreinforcing bar and inner vertical reinforcing bar engaging holes in thebrick spaced-apart at each side of a longitudinal axis of the brick.

In a further embodiment, the outer vertical reinforcing bar and theinner vertical reinforcing bar are laterally offset in each brick,engaging longitudinally spaced-apart holes in the brick.

In another embodiment, a pair of spaced-apart transverse reinforcingbars are mounted between at least two adjacent rows of brick.

In another embodiment, pairs of spaced-apart transverse reinforcing barsare mounted between all the rows of bricks.

In a further embodiment, the cladding panel has mounting means forattachment of the cladding panel to a support structure. Typically, themounting means will be provided at a rear of the panel. The mountingmeans may be attached to the rear surface of the panel by any suitablefasteners. Alternatively, the mounting means may be embedded in thepanel structure. In this construction, the mounting means may be engagedby the reinforcing bars passing through the cladding panel.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more clearly understood by the followingdescription of some embodiments thereof, given by way of example only,with reference to the accompanying drawings, in which:

FIG. 1 is an elevational view of a cladding panel according to theinvention;

FIG. 2 is a plan view of the cladding panel;

FIG. 3 is a detail end elevational view of the cladding panel;

FIG. 4 is a perspective view of the cladding panel;

FIG. 5 is an enlarged detail cut-away perspective view showing portionof the cladding panel;

FIG. 6 is an enlarged detail side sectional view taken along the lineVI-VI of FIG. 2;

FIG. 7 is an elevational view of another cladding panel according to asecond embodiment of the invention;

FIG. 8 is a plan view of another cladding panel according to a thirdembodiment of the invention;

FIG. 9 is a detail plan view showing a cladding panel assembly accordingto another embodiment of the invention;

FIG. 10 is an enlarged perspective view of a brick used in constructionof the cladding panel; and

FIGS. 11 to 16 show sequential stages in a method of manufacture of thecladding panels according to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings and initially to FIGS. 1 to 6 thereof, thereis illustrated a cladding panel according to the invention, indicatedgenerally by the reference numeral 1. The cladding panel 1 comprises aplurality of bricks 2 stacked in a number of rows 3. Verticalreinforcing bars 4 extend through the bricks 2 between a top 5 and abottom 6 of the panel 1. Mortar 7 is provided between the bricks 2.Transverse reinforcing bars 12 are embedded in the mortar 7 between eachrow 3 of the bricks 2.

Referring to FIG. 10, the bricks 2 are conventional building bricks witha number of spaced-apart through holes 8 extending between a top face 9and a bottom face 10 of each brick 2. Each brick 2 has a length L of 215mm, a width W of 105 mm and a depth D of 65 mm. Each hole 8 has adiameter of 20 mm. As can be seen in the drawings, two rows of fivespaced-apart holes 8 are provided. The vertical reinforcing bars 4extend through the bricks 2 in each row of bricks between the top 5 andbottom 6 of the cladding panel 1, as can best be seen in FIG. 3.

It will be noted that all of the bricks 2 in the cladding panel 1 areengaged by the vertical reinforcing bars 4. Each full brick 2 is engagedby two of the vertical reinforcing bars 4. One of said two verticalreinforcing bars 4 engages in one of the holes 8 in the front row ofholes in the brick 2 and the other vertical reinforcing bar 4 engages inone of the holes 8 in the rear row of vertical holes 8 in the brick 2.Thus, effectively, a front row of spaced-apart vertical reinforcing bars4 is provided, together with a rear row of spaced-apart verticalreinforcing bars 4 extending through the panel 1. Also, the two verticalreinforcing bars 4 which engage each brick 2 are offset beingspaced-apart at opposite sides of a central longitudinal axis X of thebrick 2 and are also laterally offset in each brick 2 engaginglongitudinally spaced-apart holes 8 in the brick 2 as best seen in FIG.5.

As shown in FIGS. 1 and 4 the bricks 2 in each row 3 of bricks 2 areoffset from the next adjacent row 3 of bricks 2 in similar fashion to aconventional brick wall construction.

As best seen in FIG. 5, pairs of transverse reinforcing bars 12 aremounted between each row 3 of bricks 2 and extend between opposite ends16, 17 of the wall panel 1, being embedded in the mortar 7. Such pairsof transverse reinforcing bars 12 may be provided between some or all ofthe rows 3 of bricks 2, as required.

Although not shown in the drawings, tie elements may be mounted on arear face of the cladding panel 1 or embedded in the cladding panel 1and projecting outwardly of the rear face of the cladding panel 1 forconnection to a support structure on a building for mounting thecladding panel 1 on a building structure.

Referring now to FIG. 7, another prefabricated reinforced masonry panelaccording to a second embodiment of the invention is shown and indicatedgenerally by the reference numeral 20. Parts similar to those describedpreviously are assigned the same reference numerals. In this case, anumber of openings 21 are provided in the wall panel 20 for reception ofwindows.

Referring now to FIG. 8, another prefabricated reinforced masonry panelis shown and indicated generally by the reference numeral 30. Partssimilar to those described previously are assigned the same referencenumerals. In this case, a pair of spaced-apart brick panels 1 areprovided between which is sandwiched an intermediate layer 31. Saidintermediate layer 31 may comprise insulation or alternatively it couldcomprise a reinforced concrete layer.

Referring to FIG. 9, there is shown another prefabricated reinforcedmasonry panel assembly, indicated generally by the reference numeral 40.Parts similar to those described previously are assigned the samereference numerals. In this case, the masonry panel 40 comprises anouter brick panel 1, an intermediate insulation panel 41 and an innerpanel 42 of reinforced concrete material. The outer brick panel 1 andinner reinforced concrete panel 42 are tied together in any suitablefashion and the insulation material 41 mounted therebetween. UprightT-section posts 45 are associated with the panels 40. A laterallyextending tongue 46 on the post 45 engages in an associated groove 47formed at each end of the masonry panel 40. Thus, a masonry panel 40 canbe mounted between a pair of the pillars 45 in constructing andsupporting a wall formed of the panels 40.

Referring now in particular to FIGS. 11 to 16, a method formanufacturing the prefabricated reinforced brick panels 1 will bedescribed. A plurality of bricks 2 are laid face down on a horizontalsupport surface 50 of a panel forming bed 51 in a spaced-apart arrayleaving gaps 52 between the bricks 2 for reception of the mortar 7. Saidarray comprises a number of juxtaposed rows of bricks 2, the bricks 2 ineach row of bricks being staggered relative to the bricks in eachadjacent row of bricks 2. The through holes 8 in the bricks areoverlapped in adjacent rows of bricks 2 when forming the array on thebed 51. Rubber spacer strips 53 are mounted in the gaps 52 between thebricks 2 on the bed 51 and seal between the bricks 2 and the bed 51. Anumber of spaced-apart outer vertical reinforcing bars 54 are insertedthrough the overlapping holes 8 in the bricks 2 between a top row of thebricks 2 and a bottom row of the bricks 2 in said array of bricks on thebed 51 (FIG. 12). Next, a first transverse reinforcing bar 12 is laidacross the outer reinforcing bars 54 (FIG. 13) along at least one of thegaps 52 between the rows of bricks 2. Then a number of inner verticalreinforcing bars 56 are inserted through the holes 8 in the bricks 2 toextend between the top row of bricks 2 and the bottom row of bricks 2 inthe array of bricks mounted on the bed 51 (FIG. 14). A second transversereinforcing bar 12 is mounted on top of the inner reinforcing bars 56(FIG. 15) in the gaps 52 between the rows of bricks 2. A liquid mortaris prepared from a mixture of special fine sand, cement and water.Further additives may also be included, for example an additive toimprove flowability without segregation. The liquid mortar is pouredinto the gaps 52 filling the gaps 52 and the holes 8 in the bricks 2.The mortar 7 is allowed to set and then the prefabricated reinforcedmasonry panel 1 is removed from the bed 51.

The reinforcing bars preferably comprise rebar of suitable size. Forexample the vertical reinforcing bars 4,54,56 will typically be in theorder of 8 mm-10 mm and the transverse reinforcing bars 12 may by in theorder of 6 mm. The transverse reinforcing bars 12 are provided in one ormore courses, in some cases in every second course, and in some cases inevery course.

The mortar should be free flowing to readily easily and quickly fill thegaps between the bricks and the holes in the bricks whilst at the sametime avoiding segregation of the components.

In use, a number of the cladding panels 1 are mounted on an exterior ofa building structure to provide a brick wall façade on the buildingstructure. Any suitable mounting means may be provided for mounting thepanels 1 and such mounting of cladding panels on support structures iswell known in the art.

The invention is not limited to the embodiments hereinbefore describedwhich may be varied in both construction and detail within the scope ofthe appended claims.

1. A method for manufacturing a prefabricated reinforced masonry panel,including the steps: laying a plurality of bricks face down on ahorizontal support surface of a panel forming bed in a spaced-apartarray leaving gaps between the bricks for reception of mortar, saidarray comprising a number of juxtaposed rows of bricks, the bricks ineach row of bricks being staggered relative to the bricks in eachadjacent row of bricks, each brick having a plurality of spaced-apartthrough holes extending between a top and a bottom of the brick,overlapping said holes in adjacent rows of bricks when forming saidarray, inserting a number of spaced-apart outer vertical reinforcingbars through said overlapping holes in the bricks in alignment, saidouter vertical reinforcing bars extending between a top row of thebricks and a bottom row of the bricks in said array of bricks, laying afirst transverse reinforcing bar across said outer vertical reinforcingbars along at least one of the gaps between rows of bricks, inserting anumber of inner vertical reinforcing bars through said overlapping holesin the bricks in alignment, said inner vertical reinforcing barsextending between the top row of bricks and the bottom row of bricks insaid array of bricks and spaced above the outer vertical reinforcingbars on the bed, preparing a liquid mortar and pouring said liquidmortar into the gaps between the bricks and through the holes in thebricks, allowing the mortar to set to form the prefabricated reinforcedmasonry panel, and removing the prefabricated reinforced masonry panelfrom the bed.
 2. The method as claimed in claim 1, wherein the methodincludes laterally offsetting the inner and outer vertical reinforcingbars.
 3. The method as claimed in claim 1, wherein the method includesinserting two vertical reinforcing bars through each brick.
 4. Themethod as claimed in claim 3, wherein the method includes inserting oneouter vertical reinforcing bar and one inner vertical reinforcing barthrough each brick.
 5. The method as claimed in claim 1, wherein themethod includes laying a second transverse reinforcing bar across saidinner vertical reinforcing bars along at least one of the gaps betweenrows of bricks prior to pouring the liquid mortar into the gaps betweenthe bricks.
 6. The method as claimed in claim 1, wherein the methodincludes laying first and second transverse reinforcing bars in all thegaps between the rows of bricks.
 7. The method as claimed in claim 1,wherein each transverse reinforcing bar extends between opposite sidesof the brick array.
 8. The method as claimed in claim 1, wherein thereinforcing bars comprise rebar.
 9. The method as claimed claim 1,wherein the method includes preparing a liquid mortar by mixing togethera fine sand, cement and water.
 10. The method as claimed in claim 1,wherein the method includes the step of arranging the bricks on the bedfor forming an ope in the wall panel.
 11. The method as claimed in claim1, wherein the method includes providing means for sealing between aface of each brick and the bed.
 12. The method as claimed in claim 11,wherein said sealing means extends into the gaps between the bricks. 13.The method as claimed in claim 12, wherein said sealing means comprisesresilient sealing elements mounted on the bed in the gaps between thebricks.
 14. A prefabricated reinforced masonry panel, including: aplurality of bricks arranged in a spaced-apart array of bricks withmortar between the bricks, said array comprising a number ofsuperimposed rows of bricks, the bricks in each row of bricks beingstaggered relative to the bricks in each adjacent row of bricks, eachbrick having a plurality of through holes extending between a top and abottom of the brick, holes in each brick being in alignment withassociated holes in vertically adjacent bricks, a transverse reinforcingbar mounted between at least two adjacent rows of bricks, a number ofspaced-apart vertical reinforcing bars extending through aligned holesin the bricks between a top row of the bricks and a bottom row of thebricks in the brick array, two vertical reinforcing bars extendingthrough each full brick in the array.
 15. The prefabricated reinforcedmasonry panel as claimed in claim 14, wherein an outer verticalreinforcing bar and an inner vertical reinforcing bar extend througheach brick, said outer vertical reinforcing bar and inner verticalreinforcing bar engaging holes in the brick spaced-apart at either sideof a longitudinal axis of the brick.
 16. The prefabricated reinforcedmasonry panel as claimed in claim 15, wherein the outer verticalreinforcing bar and the inner vertical reinforcing bar are laterallyoffset in each brick, engaging longitudinally spaced-apart holes in thebrick.
 17. The prefabricated reinforced masonry panel as claimed inclaim 14, wherein a pair of spaced-apart transverse reinforcing bars aremounted between at least two adjacent rows of brick.
 18. Theprefabricated reinforced masonry panel as claimed in claim 14, whereinpairs of spaced-apart transverse reinforcing bars are mounted betweenall the rows of bricks.